Rotor, motor, pump and cleaning apparatus

ABSTRACT

A rotor, motor, pump and a cleaning apparatus are provided. The rotor includes a shaft and two magnets fixed to the rotary shaft. Each magnet comprises a radial outer surface, a radial inner surface, and two connecting surfaces that connect the radial outer surface and the radial inner surface at opposite ends of the magnet. The radial outer surface has an arc section. The radial inner surfaces of the two magnets cooperatively define an inner bore for the shaft to pass therethrough. A ratio of a pole arc angle of each magnet to a 180-degree angle is in the range of 0.75 to 0.95.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claims priorities under 35U.S.C. § 119(a) from Patent Application No. 201410765091.8 filed in ThePeople's Republic of China on 11 Dec. 2014 and Patent Application No.201510323877.9 filed in The People's Republic of China on 12 Jun. 2015.

FIELD OF THE INVENTION

This invention relates to motors and in particular, to a permanentmagnetic rotor for a motor.

BACKGROUND OF THE INVENTION

Permanent magnetic rotors usually include a rotary shaft and permanentmagnets fixed to the rotary shaft. The permanent magnet may be anannular magnet having a plurality of magnetic poles arranged in acircumferential direction. The permanent magnet may also include aplurality of separate arc magnets. The annular magnet usually has a highcost. For some applications such as the drain pump for dishwashers, themotor is usually required to produce low vibration.

SUMMARY OF THE INVENTION

Thus, there is a desire for a low cost permanent magnetic rotor havinglow cost and producing low vibration.

In one aspect, a synchronous motor is provided. The motor includes astator and a permanent magnetic rotor rotatable relative to the stator.The rotor comprises a rotary shaft and two magnets fixed to the rotaryshaft. Each magnet comprises a racial outer surface, a radial innersurface, and two connecting surfaces that connect the radial outersurface and the radial inner surface at opposite ends of the magnet. Theradial outer surface has an arc section. The radial inner surfaces ofthe two magnets cooperatively define an inner bore for the rotary shaftto pass therethrough. The stator comprises a stator core and statorwindings wound around the stator core. When the stator windings areconnected in series to an alternating current power supply, the rotorrotates at a constant speed of 60 f/p RPM during a steady state, where fis the frequency of the alternating current power supply, and p is thenumber of pole pairs of the permanent magnetic rotor. The stator corecomprises a pair of opposing poles and a yoke connected between thepoles. Each pole has a pole arc surface facing the rotor, with an airgap formed between the pole arc surface and the rotor. A ratio of a polearc angle of each magnet to a 180-degree angle is in the range of 0.75to 0.94.

Preferably, the pair of poles comprises opposing circumferential endportions spaced apart from each other.

Preferably, a ratio of a distance between the circumferential endportions to a minimum width of the air gap is less than 2.

Preferably, the pole arc surface is concentric with the rotor such thata uniform main air gap is formed between the pole arc surface and therotor; an inward-recessed startup groove is formed in the pole arcsurface, and the startup groove and the rotor form a non-uniform air gaptherebetween.

Preferably, the two permanent magnets are fixed to the rotary shaft byan over-molding piece, an outer surface of the over-molding piece isconcentric with the rotary shaft, the two connecting surfaces of eachmagnet are coplanar, and a ratio of a distance between two outer ends ofthe two connecting surfaces to a diameter of the outer surface of theover-molding piece is in the range of 0.82 to 0.95.

Preferably, the radial outer surface of each magnet further includes twoplane sections extending respectively from two circumferential ends ofthe arc section to the connecting surfaces, two plane sections of theradial outer surfaces of the two magnets at one same side are coplanar,and a distance between two circumferential ends of these two coplanarplane sections is in the range of 2 mm to 9.5 mm.

In another aspect, a rotor is provided which comprises a rotary shaftand two magnets fixed to the rotary shaft. Each magnet comprises aradial outer surface, a radial inner surface, and two connectingsurfaces that connect the radial outer surface and the radial innersurface at opposite ends of the magnet. The radial outer surface has anarc section. The radial inner surfaces of the two magnets cooperativelydefine an inner bore for the rotary shaft to pass therethrough. A ratioof a pole arc angle of each magnet to a 180-degree angle is in the rangeof 0.75 to 0.94.

Preferably, a ratio of a pole arc angle of each magnet to a 180-degreeangle is in the range of 0.9 to 0.94.

Preferably, the two permanent magnets are fixed to the rotary shaft byan over-molding piece, an outer surface of the over-molding piece isconcentric with the rotary shaft, the two connecting surfaces of eachmagnet are coplanar, and a ratio of a distance between two outer ends ofthe two connecting surfaces to a diameter of the outer surface of theover-molding piece is in the range of 0.82 to 0.95.

Preferably, the radial outer surface of each magnet further includes twoplane sections extending respectively from two circumferential ends ofthe arc section to the connecting surfaces, two plane sections of theradial outer surfaces of the two magnets at one same side are coplanar,and a distance between two circumferential ends of these two planesections is in the range of 2 mm to 9.5 mm.

Preferably, the distance between the two circumferential ends of thesetwo plane sections is in the range of 2 mm to 2.5 mm.

Preferably, the two permanent magnets are fixed to the rotary shaft byan over-molding piece, the radial outer surface of each magnet furtherincludes two plane sections extending respectively from twocircumferential ends of the arc section to the connecting surfaces, twoplane sections of the radial outer surfaces of the two magnets at onesame side are coplanar, the over-molding piece defines a positioninggroove at an area where the two magnets contact with each other, withthe two plane sections at the same side of the two magnets completelyexposed.

In another aspect, a motor is provided which includes a stator and arotor as described above.

In another, a pump is provided. The pump includes a pump housing havinga pump chamber, an inlet and an outlet in communication with the pumpchamber, an impeller rotatably disposed in the pump chamber, and a motorfor driving the impeller. The motor comprises a stator and a rotor asdescribed above.

In still another aspect, a cleaning apparatus is provided. The cleaningapparatus includes a cleaning chamber, a water supply passage forsupplying cleaning water to the cleaning chamber, a drain passage fordrainage of water, and a drain pump for pumping the cleaning water inthe cleaning chamber to the drain passage. The drain pump comprises thefeatures of the pump as described above.

In comparison with the conventional arc magnets, the pole arc angle ofthe magnet of the rotor of the present embodiment is increased, whichcan reduce the cogging torque of the motor, thus making the rotation ofthe rotor smoother. In comparison with the annular magnet, the cost ofthe magnet of the present embodiment is reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention will now be described, by way ofexample only, with reference to figures of the accompanying drawings. Inthe figures, identical structures, elements or parts that appear in morethan one figure are generally labeled with a same reference numeral inall the figures in which they appear. Dimensions of components andfeatures shown in the figures are generally chosen for convenience andclarity of presentation and are not necessarily shown to scale. Thefigures are listed below.

FIG. 1 illustrates a pump according to one embodiment of the presentinvention.

FIG. 2 is an axial cross-sectional view of the pump of FIG. 1.

FIG. 3 is an axial cross-sectional view of a motor rotor of the pump ofFIG. 1.

FIG. 4 illustrates a magnet of the rotor of FIG. 3.

FIG. 5 is a radial cross-sectional view of the motor rotor of FIG. 3.

FIG. 6 is a partial, plane view of a motor of the pump of FIG. 1.

FIG. 7 is a plane view of a stator core of the motor of FIG. 6.

FIG. 8 illustrates another embodiment of insulating winding brackets ofthe stator of the motor of FIG. 6.

FIG. 9 is a view showing the insulating winding brackets of the statorof the motor of FIG. 6 are arranged end to end in the horizontaldirection.

FIG. 10 illustrates a pump housing cover body of the pump of FIG. 1.

FIG. 11 is a view of the pump of FIG. 1 with the pump housing cover bodyremoved.

FIG. 12 illustrates mounting structures of the motor rotor of the pumpof FIG. 1.

FIG. 13 is a bottom view of a bottom plate of the pump of FIG. 1.

FIG. 14 illustrates an impeller of the pump of FIG. 1.

FIG. 15 illustrates a dishwasher employing the pump according to oneembodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1 and FIG. 2, a pump 10 according to one embodiment ofthe present invention includes a pump housing 14 having a pump chamber12, an inlet 16 and an outlet 18 in fluid communication with the pumpchamber 12, an impeller 20 rotatably disposed in the pump chamber 12,and a motor 22 for driving the impeller 20. Preferably, the motor 22 isa synchronous motor including a stator and a rotor 26 rotatable relativeto the stator. The pump described herein is particularly suitable foruse in cleaning apparatus such as dish washers or laundry machines.

Referring to FIG. 3 through FIG. 5, the rotor 26 includes a rotary shaft28 and magnets 30 fixed to the rotary shaft 28. In the illustratedembodiment, the rotor 26 includes two permanent magnets 30 forming twopoles with opposite polarities. The permanent magnets 30 are fixed tothe rotary shaft 28 by an over-molding piece 32. The over-molding piece32 includes an inner ring 34, an outer ring 36, and two end plates 38disposed to interconnect opposite axial ends of the inner and outerrings 34, 36. The outer ring 36 is over-molded on the magnets 30 and hasan outer surface concentric with the rotary shaft 28. The inner ring 34is over-molded on the rotary shaft 28. The two magnets 30 are fixedradially between the inner ring 34 and the outer ring 36 and fixedaxially between the two end plates 38. A concave-convex structure 39 isformed on an outer surface of the rotary shaft 28 to strengthen thebonding force between the over-molding piece 32 and the rotary shaft 28.Each magnet 30 covers a half of the circumference along thecircumferential direction, including a radial outer surface 40, a radialinner surface 42, and two connecting surfaces 44 that connect the radialouter surface 40 and the radial inner surface 42 at opposite ends of themagnet 30. Preferably, the two connecting surfaces 44 are plane surfacesand coplanar. The radial outer surface 40 includes an arc section 46 andtwo plane sections 48 extending from opposite circumferential ends ofthe arc portion 46 to the connecting surfaces 1/1. The magnets 30 may besintered from powder material. The plane sections 48 may be used toposition the formed magnet 30 for subsequent processing such asgrinding. The arc section 46 of the outer surface 40 may be concentricwith the radial inner surface 42. The radial inner surfaces 42 of thetwo magnets 30 cooperatively define an inner bore 50 for the rotaryshaft 28 to pass therethrough. The inner ring 34 of the over-moldingpiece 32 is formed between the radial inner surface 42 and the rotaryshaft 28.

Preferably, a ratio of a pole arc angle θ of each magnet 30 to the angleof 180 degrees is in the range of 0.75 to 0.94, and more preferably inthe range of 0.9 to 0.94. The term “pole arc angle” as used hereinrefers to the angle formed by hypothetical lines connecting the twocircumferential ends of the arc section 46 of the radial outer surface40 and a center axis of the rotary shaft 28. The two plane surfacesections 48 of the radial outer surfaces 40 of the two magnets 30 at onesame side are coplanar. A distance d1 between two circumferential endsof the two coplanar plane surface sections 48 is in the range of 2 mm to9.5 mm. A ratio of a distance d2 between two outer ends of the twocoplanar connecting surfaces 44 to a diameter d3 of the outer surface ofthe over-molding piece 32 is in the range of 0.82 to 0.95. In oneembodiment, the pole arc angle θ of the magnet 30 is greater than 166degrees, and the distance d1 between the two circumferential ends of thetwo coplanar plane surface sections 48 is in the range of 2 mm to 2.5mm. The axial end of the outer ring 36 of the over-molding piece 32defines at least two positioning grooves 52 spacedly disposed in thecircumferential direction, for positioning the two magnets 30 during theprocess of forming the over-molding piece 32. Each positioning groove 52is disposed at an area where the two magnets 30 contact with each other,with the two plane surface sections 48 at the same side of the twomagnets 30 completely exposed.

In comparison with the conventional arc magnet, the pole arc angle ofthe magnet of the rotor in the present embodiment is increased, whichreduces the cogging torque of the motor, making rotation of the rotorsmoother. In comparison with the ring-shaped magnet, the arc magnet ofthe present embodiment reduces the cost.

Referring to FIG. 6 and FIG. 7, the stator includes a stator core 54 andstator windings 56 wound around the stator core 54. In the presentembodiment, the stator core 54 includes a bottom 58, two branches 60extending from opposite ends of the bottom 58, and a pair of opposingpoles 62 formed on the two branches 60. Preferably, the bottom 58 isbar-shaped, the two branches 60 extend in parallel from opposite ends ofthe bottom 58, and the two poles 62 are formed on the two branches 60 atends thereof away from the bottom 58. Each pole 62 includes two sidesurfaces 64, 65 extending from the corresponding branch 60 andsubstantially parallel to the bottom 58 and a recessed pole arc surface66 between the two side surfaces 64 and 65. The outer surface of therotor faces the pole arc surface 66, with an air gap formedtherebetween.

Preferably, the bottom 58 and the two branches 60 may be separatelyformed. The bottom 58 may be formed by a stack of multiple plate-shapedbottom members, and the branch 60 may be formed by a stack of multipleplate-shaped branch members. Each of the bottom members and branchmembers defines an assembly hole 68 for mounting the stackedplate-shaped member together. A protrusion 70 projects from an endsurface of an end of each branch 60 adjacent the bottom 58, and theopposite ends of the bottom 58 correspondingly form two recessedportions 72. After the bottom members and branch members are assembledto form their respective lamination structures, the protrusions 70 ofthe two branches 60 are snappingly connected with the two recessedportions 72 of the bottom 58 to form the stator core. Alternatively, theprotrusion 70 may be formed on the bottom 58 and the recessed portion 72may be formed in the branch 60. In the present embodiment, a maximumwidth b1 of the bottom 58 is not greater than a minimum distance b2between the two branches 60 after they are spliced together. A maximumlength b3 of the bottom 58 is not greater than a maximum distance b4between the side surface 64 of the branch 60 facing the bottom and thefarthest point of the end of the branch 60 adjacent the bottom (thedistal end of the protrusion 70 in the present embodiment). In thestator core as constructed above, the bottom 58 may be formed by thematerial between the two branches 60 that was removed during the processof forming the branches 60, thus saving the material and hence reducingthe cost. In addition, the maximum length b3 of the bottom 58 may begreater than a distance b5 between the side surface 64 of the branch 60facing the bottom 58 and the end surface of the end of the branch 60adjacent the bottom 58.

The two stator poles 62 form opposing circumferential end portions 74 ateach of two circumferential ends of the stator poles. An open slot 75 isdefined between the opposing circumferential end portions, which forms alarge magnetic resistance and reduces magnetic leakage. The pole arcsurfaces 66 of the stator poles 62 and the outer surface of the rotor 26form a substantially uniform air gap therebetween. The phraseology“substantially uniform air gap” refers to the situation where a uniformair gap is formed between most part of the stators and most part of therotor, and only a few part of the air gap is non-uniform. Preferably,the pole arc surfaces 66 of the stator poles are concentric with therotor thus forming a uniform main air gap 76. Each pole arc surface 66forms an inward-recessed startup groove 78, such that a non-uniform airgap is formed between the startup groove 78 and the outer surface of therotor 26. Preferably, the two startup grooves 78 of the pole arcsurfaces of the two poles 62 are symmetrical with respect to a diameterof the rotor and each extend from a corresponding one of thecircumferential end portions 74. This configuration can ensure that apole axis S1 (FIG. 5) of the rotor 26 deviates an angle from a centeraxis S2 of the stator pole 62 when the rotor 26 is stationary, such thatthe rotor has a fixed starting direction each time the motor is poweredon. The pole axis refers to the boundary between two different magneticpoles (the two magnets in this present embodiment), and the center axisof the stator pole refers to a line passing centers of the two poles 62.

Preferably, a ratio of a distance al between the two opposedcircumferential end portions 74 of the two stator poles to a minimum airgap (the main air gap between the pole arc surface and the rotor in thepresent embodiment) between the pole arc surface of and the rotor isless than 2.

In the present embodiment, the two open slots 75 have the same anduniform width and are parallel to the length direction of the branches60. Alternatively, each open slot 75 may have a non-uniform width. Inthis case, the distance al between the two opposed circumferential endportions 74 as described above refers to the minimum width of the openslot 75.

The motor configuration of the present embodiment can ensure that therotor has the fixed starting direction and, at the same time, reduce thecogging torque of the motor thus making the rotation of the rotorsmoother.

Referring to FIG. 8 and FIG. 9, preferably, the stator includes a pairof stator windings 56 respectively wound around insulating windingbrackets 80 of the two branches 60 of the stator core 54. The motorfurther includes a circuit board 82 (FIG. 2) mounted to the insulatingwinding brackets 80 in a direction parallel to the branches 60. Anoverheat protector 84 is mounted to the circuit board 82. The overheatprotector 84 is disposed between the circuit board 82 and the two statorwindings 56 and can cut off the power supply in case the temperature ofeither of the windings 56 is over high. The two stator windings 56 maybe formed by winding two separate conductor wires 86 which are thenelectrically connected to each other. Each conductor wire 86 has anincoming terminal 88 and an outgoing terminal 90. The two windings maybe formed by winding the two conductor wires 86 at the same time, whichis time saving. The two incoming terminals 88 of the two stator windings56 are located at lengthwise ends of the parallel branches 60 and aredisposed at inner layers of the windings. The two outgoing terminals 90are located at the other lengthwise ends of the parallel branches 60 andare disposed at outer layers of the windings. The insulating windingbracket 88 includes a tubular portion 92 and end walls 94 extendingoutwardly from opposite ends of the tubular portion 92. A winding space95 is formed between a radial outer surface of the tubular portion 92and axially opposing surfaces of the two end walls 94 for receiving thewindings 56.

The end walls 94 of the two insulating winding brackets 80 at the sidewhere the incoming terminals 88 are disposed each form a wire guidingslot 96. The two incoming terminals 96 of the two stator windings 56 arerouted from an outside of the winding brackets 80 through the wireguiding slots 96 to the winding spaces 95 at the inside of the windingbrackets 80. An isolating wall 98 is formed between the wire guidingslot 96 and the winding space 95 at the inside of the winding bracket.The isolating wall 98 extends to the outer surface of the tubularportion 92. The incoming terminal 88 is blocked by the isolating wall 98and does not enter the winding space until reaching the outer surface ofthe tubular portion 92. Therefore, the incoming terminal 88 is isolatedfrom each layer of coil in the winding space 95, thus avoidingshort-circuit of the coils due to frictional contact between theincoming terminal and the coils in the winding space which scrapes offthe insulating layer of the conductor wire. Preferably, the two outgoingterminals 90 may be soldered to the circuit board 82 and electricallyconnected such that the two windings 56 are connected in series. The twoincoming terminals 88 of the two windings 56 may be powered by anexternal single-phase alternating current power supply. Preferably, asshown in FIG. 9, the two insulating winding brackets 80 are integrallyformed and are arranged in the length direction to have a bar shape.After the two windings 56 are wound around the winding brackets 80, thebar-shaped two winding brackets 80 are bent to be parallel to eachother. The two parallel winding brackets 80 are then attached around thetwo parallel branches 60 of the stator core 54. Preferably, the twoincoming terminals of the two windings 56 are disposed at two distalends of the bar-shaped two winding brackets 80 away from each other ordisposed at two adjacent ends of the bar-shaped two winding brackets 80at a central portion thereof, and the winding direction of the twowindings are opposite to each other. As such, once the two windingbrackets are bent to be parallel to each other, the two incomingterminals of the two windings are disposed at the same ends, and themagnetic fields generated by the two windings connected in series do notcancel out each other.

Referring to FIG. 10 through FIG. 12, the pump housing 14 includes acover body 100, a bottom plate 102 mounted to the cover body 100. Thecover body 100 is hermetically connected to the bottom plate 102 by asealing ring 104. Preferably, the sealing ring 104 is positioned in aradial groove 106 of the bottom plate 102 to prevent the sealing ring104 from becoming disengaged from the bottom plate 102 before the coverbody 100 is mounted to the bottom plate 102. The cover body 100 includesa top plate 108, and a side enclosing plate 110 interconnecting the topplate 108 and the bottom plate 102. The inlet 16 extends generallyaxially outwardly from the top plate 108, and the outlet 18 extends fromthe side enclosing plate 110 in a direction generally perpendicular tothe axial direction. The cover body 100 and the bottom plate 102 formthe pump chamber 12 therebetween, and the impeller 20 is rotatablydisposed in the pump chamber 12.

Snap locking structures are formed between the cover body 100 and thebottom plate 102. The snap locking structures may be snappingly lockedwith each other by relative circumferential rotation between the bottomplate 102 and the cover body 100. Preferably, a plurality ofcircumferentially-extending locking slots 112 is formed at an outercircumferential edge of the bottom plate 102, and a plurality ofcircumferentially-extending protrusions 113 is correspondingly formed onan outer surface of the cover body 100. An axial width of thecircumferentially-extending protrusions 113 gradually decreases in adirection of inserting into the circumferentially-extending lockingslots 112. A resilient arm 114 is formed at the outer circumferentialedge of the bottom plate 102, which extends obliquely upwardly. Theresilient arm has a free end with a step 116 recessed downwardly withrespect to a body of the arm. A block 118 is formed on the outer surfaceof the cover body 100. When the cover body 100 is rotated in a clockwisedirection, the circumferentially-extending protrusions 113 of the coverbody 100 are inserted into their respective circumferentially-extendinglocking slots 112 of the bottom plate 102, and the block 118 slides overthe resilient arm 114. Once the circumferentially-extending protrusions113 are rotated to form interference-fit with their respective lockingslots 112, the block 118 just slides to the step 116 which preventsreverse rotation of the cover body 100.

The bottom plate 102 includes a pump chamber bottom wall 122 having anopening 120, and a rotor housing 124 extending integrally axially andoutwardly from the opening 120. A fixed end cap 126 is mounted to oneend of the rotor housing 124 adjacent the opening 120. One end of therotary shaft 28 passes the end cap 126 and enters the pump chamber 12 toconnect to the impeller 20 for driving the impeller 20 to rotate.Opposite ends of the rotary shaft 28 may be respectively supported by abearing 128 disposed in the end cap 126 and a bearing 130 disposed atanother end of the rotor housing 124 away from the opening 120.

Preferably, the bearing 128 may be mounted to the end cap 126 via ashock absorber 132. The bearing 128 is cylindrical in shape and includesa ridge 134 extending circumferentially on an outer surface of thebearing 128. An inner surface of the shock absorber 132 forms a groove136 for engaging with the ridge 134. This construction can ensure theconcentricity between the bearing 128 and the rotor. The bearing 130 maybe supported by a bearing seat 138 integrally formed with the rotorhousing 124. A plurality of internal teeth 140 is formed on an innersurface of the bearing seat 138, which leads to a non-continuous contactbetween the inner surface of the bearing seat 138 and the outer surfaceof the bearing 130. This configuration can reduce vibration generated bythe motor during operation.

The rotor housing 124 is fixed between two stator poles 62. A gap isformed between the outer surface of the rotor 26 and the rotor housing124, such that the rotor 26 can rotate relative to the rotor housing124. An axially-extending rib 142 (shown in FIG. 11) is formed on theouter surface of the rotor housing 124. Two adjacent sides of the twoinsulating winding brackets 80 at the ends adjacent the stator poles 62cooperatively form a rib 144 (FIG. 6). The rib 142 and the rib 144 arerespectively inserted into the two open slots 75 between thecircumferential end portions 74 of the two poles 62, thus limitingrelative circumferential rotation of the stator core 54. Preferably, anouter surface of the rib 142 of the rotor housing 124 is not higher thanthe side surface 65 of the stator pole 62 away from the bottom 58.

Referring to FIG. 11 and FIG. 13, the motor further includes a motorcover body 146 covering the stator windings 56 and the circuit board 82.The motor cover body 146 includes a bottom wall 148 and two sidewalls150 extending from the bottom wall 148. The two sidewalls 150 aredisposed at two sides of the stator core 54. The circuit board 82 isdisposed between the bottom wall 148 and the stator windings 56.

In the present embodiment, the motor cover body 146 and the pump housing14 are mounted to each other by snap locking structures includingprotruding blocks 152 on the sidewalls 150 and hooks 154 extendingdownwardly from the bottom plate 102. The protruding blocks 152 aresnappingly engaged with the hooks 154. The bottom plate 102 includes atleast one pair of positioning protrusions 156 corresponding to the twosidewalls 150. Each of the sidewalls 150 is sandwiched between acorresponding one of the hooks 154 and a corresponding one of thepositioning protrusions 156. Preferably, each positioning protrusion 156is aligned with a void portion of the corresponding hook 154, such thatthe corresponding sidewall 150 can be pressed by the positioningprotrusion 156 to deform toward the void portion. As such, the mountingforce between the motor cover body 146 and the pump housing 14 isstrengthened, which reduces vibration during operation of the motor.

In the present embodiment, the hooks 154 can also function as thepositioning protrusions 156 at the same time. Understandably, the pairof positioning protrusions 156 may also be separately disposedindependently of the hooks 154. In the illustrated embodiment, more thanone pair of positioning protrusions 156 are formed at each sidewall.Alternatively, a single pair of positioning protrusions 156 may beformed at each side. In the case of more than one pair of positioningprotrusions 156, each pair of positioning protrusions 156 may beseparately disposed independently of the other pair of positioningprotrusions 156. Alternatively, a bar-shaped protrusion 156 is formed ina location corresponding to an inside or outside of the sidewall, andtwo or more than two pairs of positioning protrusions 156 share thebar-shaped protrusion 156.

Chinese Patent Application Numbers 201410404474.2 and 201410404755.8 areincorporated by reference herein in its entirety. The motor of thepresent embodiment, when used in conjunction with the drive circuitdisclosed in either of the Chinese patent applications or anothersuitable drive circuit, can ensure that the rotor rotates in the samedirection during each startup. As such, in applications such as fans orwater pumps, the impeller driven by the rotor may utilize curved bladesthus enhancing the hydraulic efficiency of the fans or water pumps.Thus, smaller motors can be used for achieving the same level of output,which can reduce energy consumption. The drive circuit may be disposedon the circuit board 82. Based on magnetic pole position informationdetected by a position sensor 158 (FIG. 2), the stator windings 56 areenergized in a predetermined manner to ensure that the rotor has thefixed startup direction each time the motor is powered. In the presentembodiment, the position sensor 158 is disposed in a range of a cuteangle formed between a perpendicular line of the pole axis S1 of therotor when the rotor is stationary and a perpendicular line of thecenter axis S2 of the stator. The position sensor 158 is disposedoutside the rotor housing 124 and covered by the motor cover body 146.

Referring to FIG. 14, the impeller 20 is fixedly mounted to the rotaryshaft 28 for synchronous rotation with the rotary shaft 28. The impeller20 may be made from plastic material and includes a substrate 160 and aplurality of blades 162 spacedly mounted to the substrate 160 in thecircumferential direction. Preferably, the blades 162 of the impeller 20are arc shaped and include a group of long blades 164 and a group ofshort blades 166. The two groups of blades are alternatively disposed atthe outer circumferential edge of the substrate 160 in thecircumferential direction. A spiral flow passage 168 (FIG. 11) is formedbetween an inner surface of the pump chamber 12 and the impeller 20. Aradial cross-sectional area of the flow passage 168 gradually increasesin the circumferential direction toward the outlet 18. Under thecondition that the rotor has the fixed startup rotating direction, thearc-shaped blades and the spiral flow passage can enhance the hydraulicefficiency. A mounting post 170 is disposed at a central area of thesubstrate 160. One end of the rotary shaft 28 is fixed to the mountingpost 170 via a shaft sleeve 172. The shaft sleeve 172 may be formed froma metal material. Preferably, at an axial end of the mounting post 170away from the motor, the mounting post 170, the shaft sleeve 172 and aninjection molding portion 174, which are arranged radially inwardly,cooperatively form a continuous closed end surface. The injectionmolding portion 174 and the mounting post 170 are connected via abridging portion 176. In an alternative embodiment, the impeller 20 mayutilize straight type blades.

The pump 10 described herein is particularly suitable for use as a drainpump for cleaning apparatus such as dishwashers or laundry machines butnot limited to it. FIG. 15 illustrates a dishwasher 176 comprising adrain pump according to one embodiment of the present invention. Thedishwasher includes a cleaning chamber 178, a water supply passage 180for supplying cleaning water to the cleaning chamber 178, a drainpassage 182 for drainage of water, a circulating passage 184 forcirculating cleaning water in the cleaning chamber 178, and a controlsystem 188 having a drain pump 10 and a circulating pump 186. The drainpump 10 pumps the cleaning water in the cleaning chamber 178 to thedrain passage 182, and the circulating pump 186 pumps the cleaning waterin the cleaning chamber 178 to the circulating passage 184. It should beunderstandable that the motor described in embodiments of the presentinvention can also be used in other applications.

In the description and claims of the present application, each of theverbs “comprise”, “include”, “contain” and “have”, and variationsthereof, are used in an inclusive sense, to specify the presence of thestated item but not to exclude the presence of additional items.

Although the invention is described with reference to one or morepreferred embodiments, it should be appreciated by those skilled in theart that various modifications are possible. Therefore, the scope of theinvention is to be determined by reference to the claims that follow.

The invention claimed is:
 1. A synchronous motor comprising a stator anda permanent magnetic rotor rotatable relative to the stator, wherein therotor comprises a rotary shaft and two magnets fixed to the rotaryshaft, each magnet covers a half of the circumference of the rotaryshaft along a circumferential direction and comprises a radial outersurface, a radial inner surface, and two connecting surfaces thatconnect the radial outer surface and the radial inner surface atopposite ends of the magnet, the radial outer surface has an arcsection, the radial inner surfaces of the two magnets cooperatively forman annular surface which defines an inner bore for the rotary shaft topass therethrough; the stator comprises a stator core and statorwindings wound around the stator core the stator core comprises a pairof opposing poles and a yoke connected between the poles, each pole hasa pole arc surface facing the rotor, with an air gap formed between thepole arc surface and the rotor, a ratio of a pole arc angle of eachmagnet to a 180-degree angle is in the range of 0.75 to 0.94, whereinthe pole arc angle of each magnet is an angle formed by hypotheticallines connecting two circumferential ends of the arc section of theradial outer section of the magnet and a central axis of the rotaryshaft, and wherein the connecting surfaces of one of the magnets contactthe connecting surfaces of the other one of the magnets, the radialouter surface of each magnet further includes two plane sectionsextending respectively from the two circumferential ends of the arcsection to the connecting surfaces, two plane sections of the radialouter surfaces of the two magnets at a same circumferential end arecoplanar.
 2. The synchronous motor of claim 1, wherein the pair of polesof the stator core comprises opposing circumferential end portionsspaced apart from each other.
 3. The synchronous motor of claim 2,wherein a ratio of a distance between the opposing circumferential endportions of the pair of poles of the stator core to a minimum width ofthe air gap is less than
 2. 4. The synchronous motor of claim 1, whereinthe pole arc surface is concentric with the rotor such that a uniformmain air gap is formed between the pole arc surface and the rotor, aninward-recessed startup groove is formed in the pole arc surface, andthe startup groove and the rotor form a non-uniform air gaptherebetween.
 5. The synchronous motor of claim 1, wherein the twopermanent magnets are fixed to the rotary shaft by an over-moldingpiece, an outer surface of the over-molding piece is concentric with therotary shaft, the two connecting surfaces of each magnet are coplanar,and a ratio of a distance between two outer ends of the two connectingsurfaces to a diameter of the outer surface of the over-molding piece isin the range of 0.82 to 0.95.
 6. A rotor comprising a rotary shaft andtwo magnets fixed to the rotary shaft, each magnet covering a half ofthe circumference of the rotary shaft along a circumferential directionand comprising a radial outer surface, a radial inner surface, and twoconnecting surfaces that connect the radial outer surface and the radialinner surface at opposite ends of the magnet, the radial outer surfacehas an arc section, the radial inner surfaces of the two magnetscooperatively form an annular surface which defines an inner bore forthe rotary shaft to pass therethrough, and a ratio of a pole arc angleof each magnet to a 180-degree angle is in the range of 0.75 to 0.94,wherein the pole arc angle of each magnet is an angle formed byhypothetical lines connecting two circumferential ends of the arcsection of the radial outer section of the magnet and a central axis ofthe rotary shaft, wherein the connecting surfaces of one of the magnetscontact the connecting surfaces of the other one of the magnets, theradial outer surface of each magnet further includes two plane sectionsextending respectively from the two circumferential ends of the arcsection to the connecting surfaces, two plane sections of the radialouter surfaces of the two magnets at a same circumferential end arecoplanar.
 7. The rotor of claim 6, wherein a ratio of a pole arc angleof each magnet to a 180-degree angle is in the range of 0.9 to 0.94. 8.The rotor of claim 6, wherein the two magnets are fixed to the rotaryshaft by an over-molding piece, an outer surface of the over-moldingpiece is concentric with the rotary shaft, the two connecting surfacesof each magnet are coplanar, and a ratio of a distance between two outerends of the two connecting surfaces to a diameter of the outer surfaceof the over-molding piece is in the range of 0.82 to 0.95.
 9. The rotorof claim 6, wherein a distance between the two circumferential ends atopposite ends of the two plane sections at a same side is in the rangeof 2 mm to 2.5 mm.
 10. The rotor of claim 6, wherein the two magnets arefixed to the rotary shaft by an over-molding piece, an axial end of theover-molding piece defines two spaced positioning grooves respectivelyaligning with two junctions of the two magnets, with axial ends of thetwo plane sections at the same side of the two magnets completelyexposed from the corresponding positioning groove.
 11. A motorcomprising a stator and a rotor in accordance with claim
 6. 12. A pumpcomprising: a pump housing having a pump chamber; an inlet and an outletin communication with the pump chamber; an impeller rotatably disposedin the pump chamber; and a motor for driving the impeller, wherein themotor comprises a stator and a rotor in accordance with claim
 6. 13. Acleaning apparatus comprising a cleaning chamber, a water supply passagefor supplying cleaning water to the cleaning chamber, a drain passagefor drainage of water, and a drain pump for pumping the cleaning waterin the cleaning chamber to the drain passage, wherein the drain pumpcomprises the features of the pump in accordance with claim
 12. 14. Therotor of claim 6, wherein a distance between two circumferential ends atopposite ends of the two plane sections at a same side is in the rangeof 2 mm to 9.5 mm.
 15. The synchronous motor of claim 1, wherein adistance between two circumferential ends at opposite ends of the twoplane sections at a same side is in the range of 2 mm to 9.5 mm.
 16. Therotor of claim 1, wherein the two magnets are fixed to the rotary shaftby an overmolding piece, an axial end of the over-molding piece definestwo spaced positioning grooves respectively aligning with two junctionsof the two magnets, with axial ends of the two plane sections at thesame side of the two magnets completely exposed from the correspondingpositioning groove.